Process for impregnation of lime with carbon



July l0 `1945. A. .L ABRAMs erm.

rnomss Fon IMPREGNATION oF LIME WITH CARBON V Filed Nw. V15, 1941 y 2sheets-snee; .1

Y l 0015 B. COO/f INVENTORS ATTORNEY 10104101945; A. J., ABRA'MS mL 2,380,008

PROCESS FORIMPREGNATION OF LIME WITH CRBQN Filed Nov. 15, 1941 2 sheets-sheet 2 Ca0- @Maf/rfi@ 1- I (2z 0.456' @Malin-fw 0a/5 B, Coo/r lNvENToRs Vm MQW ATTORNEY Patented July 10, 1945` 1 I u t N UNITED STATES PATENT OFFICE assures l PRocEssFoR IMPREGNATION F LIME Wrrn CARBON Armand J. `Abramsand Louis B. Cook, Dallas, `Tex., assignors to; Socony-Vacuum Oil Company, Incorporated, New York, NrY., acorporation of New York rApplication November 15, 1941, Serial No. 419,238A p p 16 claims. (c1. zs-fzos) e e e y ,e e This invention is concerned with a method forV carbon complexes that uses materials and power the utilization of hydrocarbon gases and espe-l` l vrequirements which are cheap, abundant` and;-

cially hydrocarbon "gases Vwhicharepredomnantclosely associated as "to source.` .i ly methane, such as, for" example, natural gas. All theabove. objects, `aswell as other objects, 'I'he invention `relates particularlyto the useof 5 will be apparent from theviollowing description `suchA gases in the production of calcium carbide.. of our invention. l n l i..

Enormous quantities of gases containing ahigh For the manufacture of calcium carbide,` `our l plant as toinsure ready access to cheap and percentage of methane are readily available, and` process involves two distinct and separatesteps.

` for this reason, considerable thoughtand work- These two separate steps are (1) the Dyrolysis` has been expended in an endeavor to iind some of a light hydrocarbon gas inthe presenceoflime use for such gasesother than merely as a fuel. or limestone under what might betermed rela- Eor the most part, however, because `ofthe sta- 1 tively lmoderate temperatures so as to fprml a bility cf the methane, a `use for these gases has lime-carbon complex or mixturewhich contains remained acomplicated problem so thatQwhere` calcium and carboniin suitable ratios for the they are produced, they' are either recycled into 15 manufacture of calcium carbide,` and (2)` treatthe ground, used as fuel or flared oil. The presment of such lime-carbon complex or mixture in ent invention has developed a novel VVprocess for a separate step at substantiallyhigher temperautilizing methane-containing gases as a source of tures` to form calcium carbide therefrom.` Fur` carbon in the manufacture of useful lime-carbon thermore, each of these two steps,` when carried complexes as well as calcium carbide., Moreover, outvin our preferred manner, ls believed to be these lime-carbon complexes in certainformsare new and novel by itself as `well asthe product believed to be novel products as also is one form yielded thereby. .i

of the calcium carbide that can be produced. Althoughpossibly most normally gaseous hy- 'lhe` primary use of calcium carbide is for the drocarbons `might be used `in the process, the production of acetylene by hydrolysis. Heretorather high temperatures required for the pyrolyfore,V calcium,V carbide e has been manufactured `sis of the very light, hydrocarbons; are thought commercially by fusing a mixture of lime and A to be of considerable importance in attaining coke. However, certain limiting and inconvenient i the desired type of carbon formation with the` factors are inherent in this method, chiefly sur` lime in `the lime-carbon complex. Moreover. rounding the necessity of so locatingthe carbide other constructive uses have been found formost ofthe higher normally gaseousghydrocarbons.

abundant supplies of three` different essentials, Therefore, for thesereasons and also because namely, limestone, coke and power. there are suchtremendoussuppliesof.` light hy Accordingly, another important consideration drocarbon gases,wwe` are"concerned` primarily underlying the present invention is the fact that `with the use of methane-predi'aminatingy gases, a process is furnishedv to the art for the manu# Le., gases in which methane is the'predorninant facture of calcium carbide whose essentials, hydrocarbon. l

namely, limestone, light hydrocarbon gases and The limestone used should be in the form of power, are closely associated in cheap and abun granulesor small lumps oi such `size as to give a dant` quantities, such as, for example, in the 40 fairly free `flowing mass A size of from about 1A southwestern part of the United States. l l toaboutlZ inches has been found especially suit- Therefore, it'is an object of our invention to able as presenting a convenient `balance of volprovide an attractiveprocess for4 the utilization ume and exposed surface with proper resistance of light hydrocarbon gases. l i

Another object is to.provide a method of manusizes are, of course, notcritical and may be varied. facturing useful lime-carbon complexes, some of We shall use the term crushed limestone or which are believed novel.` a Acrushed lime to indicate generally that small A more specic Objectis to furnish an efficient lumps of suitable `particle size` are being used. .process for the manufacture of calcium carbide, The degree of pyrolysis 0f thenatural `gas or using'methane-containing gases `as the source of v50 methane-predominating gas in the pyrolysis step carbon. i e A is controlled to give a deposit of carbon on, in, or

A still more specific, but highly'important, obwith the lime of `proportions suitable for subsetogas' passage through apmasstherecf. These ject is to manufacture `calcium carbide directly `quent`carbide formation. The theoretical mol Y in a solid state from solid lime rather than in ratio is, of course, oneoi calcium oxide (lime) a fused state. i i f i V 5 to three of carbon. However,as known,.this.ratio A further object is to produce calcium carbide may be varied somewhat'iinfiiiaticeif'alseior exfrorn lime and carbon at substantially ,lgwer-telgrgfn; am peratures thaniusedllrecetoinree lEtillf-fab'otliefr :oliieeimisactmbioildeea carbon characteristics common voltages.

The pyrolyzing temperatures should be suiiicient` to give a practical rate of carbon deposition but substantially below recognized carbide-forming temperatures, as, for example, between about 850 and about l400 C. The range of about 850 C. 1562 F.) to about ll50 C. (2102 F.) is preferred because in this range the carbon formed is unique and produces a novel complex with the lime. The range of 950 to 1050 C; isconsidered optimum for our pyrolyzing step. i

Thus, in our preferred temperature range the` methane decomposes to produce a novelcomplex or'mixture with the lime. That is, the structure and constitution of this complex is not fully understood, but it is quite evident that it is different from lime, from calcium carbide. and from a simple lime-carbon mechanical mixture. vIn fact,

our complex closely resembles-a good grade metallurgical coke inglossy'luster, resistance t0 abras sion, crushing and shearing strength, whereas lime, as is well known, crushes very easily. Further, our complex is quite resistant to weathering,

whereas lime is hydrated rapidly when left ex-Y distinposed. The same features also obviously guish our complex from simple lime-carbon mixtures since the lime would retain` its characterstics in such a mixture.. Our novel complex in its preferred form having a substantially uniform dark color throughout the particle.r That is, by ourprocess we are able to produce a lime-carbon complex of variousl mol ratios, even in such low ratios of carbonto limethat the carbon is not uniformly distributed through the entire particle. However, in the preferred form of higher mol ratios, e. g., lone to one or higher, the carbon is uniformly distributed. Still further, because of the unique of our complex, plex is an V`electrical; conductor even where it has a very small ratio of carbon to lime, and where this mol ratio is atleast one to one, the complex is a suitable electrical conductor at industrially plex is easily distinguished from calcium carbide, as, for example, by its inability to be hydrolyzed to form'acetylene.

We believe that one we Iare able to obtain such a unique lime-carbon complex. wherein the carbon is so intimately and thoroughly associated with the lime, is because in the pyrolysis chamber the methane or hydrocarbon gas is distributed throughout the pores or interstices of the lime particles, and, as a result,

to carbon in intimate Y the methane decomposes association with each lime particle and throughout the entire lump. Moreover, this methane decomposition is occurring at a very high temperature. our experimental work. This work indicates that if We are to obtain our novel complex at all, and also if we are to obtain any lime-carbon mixture suitable for carbide manufacture within a comrnercially feasible time, the pyroly'sis of the hyischaracterized further by the com- On the other hand, our comof the principal reasonsV Our views on this point'are confirmed by raaaoos Y combustion-gases therein'tol Methods of heating y cause of the fact our process particles.

drocarbon gas in the presence of the lime should be carried out in the absence of large amounts of gases other than such hydrocarbon gases and the decomposition products thereof. Thus, judging from the experience of our several years of work on this problem, it appears that where, for example, combustion gases or other heating gases which oxidize carbon are introduced into the pyrolysischamber inv considerable quantity, corn-A peting ractions for carbon set in which tend to inhibit deposition of carbon in appreciable amounts,VV soV that our novel complex is not produced and rather long reaction times are required in order to obtain substantial carbon deposits.-

Therefore, for ourpreferred procedure, We have devised several methods of heating the pyrolysis chamber, in addition. to the Vobvious manners for Y doing same, which do not require 'introduction of through a confining wall, such as byV combustiongases, electrical resistance heaters, etc., could be used, Moreover, the electrical resistance heaters might be placed in direct contact with the lime A rather unique method of heating the pyrolysis chamber,

- is capable of producing a lime-carbon complexL which is an electrical conductor.` 'I'hat` is, by `recycling .a sufcientamount of this complex to thepyrolysis chamber so that the entire charge .in the chambermay'be used as a resistor, such as, for example, when this complex constitutes about 90% 'of the solids, the heating may be supplied by electrical resistance. Other methods of heating might involve carrying on simultaneously in the pyrolysis chamber an essentially exothermic reaction or reactions which permit appreciably lower temperatures to beused than are required in a'v strictly thermal operation. Y

In view of the high temperatures involved inthe pyrolysis of methane, Vsuch considerations are material.

The fact that the off gases from our preferred pyrolysis large quantities of combustion-gases, creates a Vfurther important ramication of our process,

namely, the utilization of these off gases. Such gases consist of hydrogen, carbon dioxide and some unreacted methane (or other hydrocarbonV gases) When limestone is used, and when lime is` -used directly, rather than forming it from limestone,'these gases consist only of hydrogen and methane or other hydrocarbon gases) .A The per-r centage of hydrogen in these gases is relatively high under conditions of low space velocity operation sothat its recovery is worthwhileand,'in deed, the process may be looked upon'as an efiicient method of manufacturing hydrogen. Still further, these off gases are a suitable charge for an arc furnace for the manufacture of acetylene directly and this may be done, if desired. Our novel lime-carbon'complex is a commercially importantproduct'whichhas uses other,

than for the manufacture of calciumV carbide, in fact, it is a most eiiicient material.for uses in general requiring the presence of lime and carbon. Thus, for example, our complex is eminently suitable for use in blast furnaces for ore reduction, and other specific uses will be obvious in processes where there is a simultaneous requirement for lime and carbon. The `unique characteristics of our complex are all in its favor for such uses. For instance, it is a hard material which will stand considerable handling and ship- Y ping without crushing; it weathers very slowly;

.i and the carbon is firmly secured to the lime. and

however, is afforded bechamber are not -contaminated with.

also is uniformly distributed therethrough, so that it is a non-dusting-ivproduct, Moreover, A

loose soot is not present to be handled orto present problems of retaining same ina furnace havi ing a strong draft. u Stillffurther, the complex is an electrical conductorxso thatelectrical resist-` ance furnaces may be employed where it is used.`

As noted above, we are especially concernedin this invention with the use of our complex forithe Many of the above and other advantages of our complex,` will be seen in this operation. According to our process, lime with the proper-amount of carbon which manufacture' of calcium carbide.

has been produced by'pyrolysis of light hydrocar-V,

bon gases is passed into an electric furnace where the mixture isheated for the production of calcium carbide .(CaCzl' at a substantially higher` temperature than is used'inthe pyrolysis chamber. For example, whereas the pyrolysis temperature should be around 850 to 1,150 C., the car- 'bide-forming' temperature should be above abouti 1700 C., the preferred carbide-forming temperatures being between about 1800 and about 2350 C. Therefore, it can. be seen that two distinct and separate steps are involved ln'order to obtain a product containing substantial amounts of `cal- Y cium carbide. Ourelorts to accomplish in one step the methane pyrolysis and the carbide-forming operation have been entirely.unsatisfactoryv for obtaining appreciable or, in fact, easily detectable amounts of calcium carbide.

The carbon and lime of our process may be heated to carbide-forming temperatures by the same means conventional lime and coke mixtures are heated to yield calcium carbide, as, for example, by an electric arc-type or an electric resistlime and carbon of our complex are so intimately associated that the lime will not react with the carbon susceptor of the furnace.A

As is well known, calcium carbidehas been produced heretofore in a fused state. commercial installations attain continuous production by tapping off the molten product and feeding in fresh `charges of solid lime andcoke. Our process also may be operated in this conventional manner. However, there are several innected with operating under tapping conditions.

Therefore, another far-reaching and important Present 1 tage. A

operatedrunder non-tappingconditions'.`

Eurthermore, ,asidefrom Athe advantages con-"` Y nectediwith gettingour solid calcium carbide out* Y of the furnaceaswcompared to tappingmolten 1 CaC2 and `also thefact `our CaCs is producedin Vlump form,V there is still.anotheradvantage.inwV that this preferred calcium carbide of ours `is berlleved to have a different physical structure*` That isylumpsof our product` which `do `not pass 'j through ,a molten staterappear `to be more pervious than prior calcium -carbideieven though the l i two products may. have thesaine CaCz content,"

e. g., A65 to, 85%; Therefore,g.our,highlypervious product of high CaCz content can beusedvmore eflicientlyor effectively in certain processes, las, for instance, incertain chemicalfsyntheses, `such as in treating with nitrogen to produce calcium. cyanamide. At best, the calcium carbide which has been fused and solidiiiedwould have to be crusheclf-I We are not entirely clear as to just why our lime-carboncomplex` affords the above advani However, we feel it is primarily due to the carbon being sointimately and `uniformly asso'-l ciatedcr mixed with the lime so that formation of CaCz can take place in the solid state, whereas` Y in prior processes it is necessaryto fusethe charge i in order to obtain the necessary mixingor association of `lime and carbon for forming the carbide. Hence,` it` seems` we retain at least the porous structure of thelime lumps and possibly` we increase the porosity of the lumps by the'gcarbon Y `monoxidevgas liberated during the formation of ance-type furnace. In addition, an electric inductance-type furnace might be used because the herent 'disadvantages and inconveniences conadvantage is obtained by using our novel limecarbon complex as a charge material for the carbide furnace. We have made the surprising discovery that by using this charge material, calcium carbide can be produced directly in the solid state in the form of lumps, e. g., 1A; to 2 inches in size, which contain a predominant amount of CaCz.

almost any amountof CaCz, such as, from about In fact, lumps may be made containing 5% to 90 or 95%. For practical products, however, the content of CaCz should be at least 20 or 25% and preferably above about 50 to 65%.`

We have found that with this material a carbideforming temperature can be used which is sub-` stantially,` e. g., 300 to 400 C., below the conventional carbide-forming temperatures for lime and coke charges. to operate at temperatures which .are below the melting points of the charge and calcium carbide, and, as a result; the :calcium carbide is formed directly in the same solid or lump form that the lime-carbon complex is in. Workers acquainted with carbide furnaces or other like high temperature furnaces will readily appreciate the econ- Because of this fact, we are able` the CaCz. Such a` result, of course, cannot be Y obtained where the CaCz is formed in a fused state.

Accordingly, a complete acetylene-producing operation embodyingour invention might employ all of the following steps: (l) calcining limestone to lime, (2) pyrolyzinga methane-predominating gas in thepresence of limeto form our lime-carbon complex, (3)` conversion of the lime-carbon complex to calcium carbide, (4) hydrolysis of the calcium carbide toacetylene and calcium. hydroxide, and (5) concentrating and calcining the calcium hydrate and returning the calcium oxide" produced thereby to` the system. l On lthe other hand, `at places where adequate supplies of cheap 1 i lime are available, step (l) would probably be eliminated. Also where the point of use of acetyl iene is remote from the carbide plant, as is very` usual, the hydration step (4) might be conducted A. near that point, and then step (5)` vwould be abandoned` for obvious reasons. y

In order to explain the invention 'still i more, referenceis now made to the accompanying drawings which show in diagrammatic form, suitable apparatus systems `forlcarrying out the. invention. In thesedrawings, Fig. 1 shows a complete acetyiene-producingsystem while Figures 2 and 3 show two different'types of carbide furnaces,I in each` of which, however, `the calcium duced in a Vsolid state.

Referringnow to Figure 1,` there is shown a calcining kiln of usual type, a gas pyrolysis kiln 2,

` carbide is proand a carbide furnace 3, all arranged for continuous operation. Limestonel or dried limeisludge V may be fed to calcining furnace l, through a feed device located at Land in furnace I, it will meet a combustion mixture introduced at 5 and be coni verted to calcium oxide.` The calcium oxide or through passage 6.

lime passes on in heated condition to furnace 2 Hot gases from thc calcininar furnace, departing through pipe l. pass through ,omi-es* which will result when such furnacesare,

a heat exchanger 8, vvhere they give up heat to plied by utilizing the olf gases of the pyrolyzingY *Y and the carbide-forming furnaces. `Thus, areas air introduced through pipe 9V which air, when heated, passes through pipe I to enter the cal-v cining'furnace I. This calciningfurnace I, will have the usualcharacteristics of design and operation plus suitable modifications-for vthe fuel used, and will operate at theusual temperaturesv of, say, E50-1150" C. It perhaps should be noted that dead burned lime is not objectiona'l in-this process. b l

Hot calcium oxidepasses in al heated condition .through` passage Vti into and fills the hydrocarbon gas pyrolyzing furnace 2. 1 Hydrocarbon gases,

such as,l for example, natural gas, are introduced to furnace 2 atII. If necessary,V this gas may Y be preheated in any convenient manner. Since the temperature of the bed 'of oxide is Vmaintained at about 1000 C., the gas'will crack therein to deposit carbon in and on the oxide and to produce hydrogen. kThe gas, leaving furnace 2',

at;A I2, may contain some free carbon, and if desirable, this carbon may be removed by some convenient device, such as, for example, the hot Cottrell precipitator shown as I3. The remaining gas, leaving at I4, may be utilized as fuel in the calcining furnace, together with other gaseous fuel, such as natural gas, if necessary, or may be recovered for other uses such as those mentioned hereinbefore. l Y i The carbon-carrying lime passes from furnace 2 in a heated condition through I5 into. and fills hopper 3a of the carbide furnace 3. 4Carbon separated at I3 may also be passed into 3a by pipe I8. In furnace 3, which, as shown here, is of the usual type, the lime and carbon are fused and heated by electrodes I6 and I1 toform calcium carbide in a molten state. Carbon monoxide lib' Y .erated in 3, plus such carbon dust as may accomdrawn at 23 and after concentrating and drying,

as in "nodulizing kiln 24, may be returned to process as indicated by 25.

In yFigure 2 is shown a variation of the operation, centering solely around the carbide furnace, which is applicable to our operations for manufacturing calcium carbide in the solid state from our lime-carbon complex. In this figure, 26 represents a shaft type furnace, heated by means of inductance coils 21 and susceptor 21a. The advantages incident uponthe production of carbide in lump form, as shown in Figure 2, Without the losses and inconvenience incident to a tapping furnace, as shown in Figure 1, are obvious.

Figure 3 is a further modification aimed at the production of lump carbide Without intermediate melting. 'Ihe furnace 28 of this embodiment is of the same nature as furnace 26-of Figure 2, ex-

' yielding 784 parts of a similar gray lime-'carbon Where cheap natural gasis plentiful are often close to suitable'limestone deposits` Asa result,

low cost electric power from natural gasV is availl able, and carbon fromV the natural gas is avail- Y able. A very important factor also is that our process furnishes a'constructive Vuse for the enermous stores ofk natural gas which, unlike the valuable liquid hydrocarbons, are not. being put to constructive use at this time. c

In order to describe the invention still further, several illustrative operating examples are given belowz ExampleI One hundred and fifty-six parts by weight vof calcium oxide in the form of lumps of 1i'to V1/2,` size Were treated at 100'0?` C. during a period Yof f 52 hours in which 563 partsby weight of pure methane Were passed over the lime. 'I'he rate of flow was so adjusted as to give a contact time,` of 6 seconds. At the end of this run, thetreated j f material was gray, with a bright metallic luster and had a mol ratio of A3:1, carbon to ,calcium` oxide. No free carbon was evident. 32 partsv of this lime-carboncomplex were heated to a temperature of 1700 C. (approximate) in an induction furnace such as is shown in vFigure 2, resulting in the production of 28 parts by weight of a material containing 20 per cent of calcium carbide.

l Example II Four hundred and nity-seven parts by weight of calcium oxide were treated with 1,656 parts of methane under the temperature and contact time conditions of Example I for a period of l2 hours,

mol` ratio `to V1800a C. for thirty minutes, yielding 130 parts of material containing 67' per cent of calcium carbide. The material treated retained its lump form throughout the process.

I Example `III 1920 parts by vveight of calcium oxide inthe form of 1/4" to 1 lumps were treated at 1000 C.

o during a period of 40 hours during which v'7000 parts by weight of methane were passed over the' lime. "The rate of flow was so adjusted as to give V a contact time of 3.5 seconds. At the end of this run the treated material had the samevphysical properties as the complex described in Example 1,`

and a mol ratio 324:1, carbon to calcium oxide.

cept'that in this case, furnace 28v is equipped with 122 parts by weight of this complex were heated to 1800 C. for thirty minutes, yielding parts of material containing 96 per cent of calcium carbide.

Example IV 423 parts by weight of calcium oxide werev treated with 496 parts of methane at 1200'C. during a period of 8.5 hours, and with a contact time of 3 seconds. 767 parts of a graylimecarbon complex were obtained having a mol ratio of 2.84: 1, carbon to calcium oxide, and possessing tlflie iroperties of the material described in Exam.- p e 119 parts by weight ofthe material were heated to 1800 C. for thirtyminutes, yielding 90 parts of material containing 67 per cent of calcium carbide.

In this example an appreciable amount of free step.

carbon was also obtainedduring the pyrolysis We claim:

1. The process of manufacturing calcium carbide which comprises pyrolyzing a light hydrocarbon gas in the presence of calcium oxide at a Itemperature between about 850 and about 1150 C. so as to produce a mixture `of calcium oxide and carbon of proper proportions for manufacturing calcium carbide by heating, and then heating said mixture of calcium oxide and carbon at a temperature above about 1700 C. so that calcium carbide is formed.

2. AThe-process of manufacturing calcium carbide which comprises pyrolyzing a methane-predominating gas inthe presence of crushed calcium oxide at a temperature between about 850 and about 1150 C. so as to leave a deposit of carbon with the crushed material suitable for manufacturing `calcium carbide, and then heating said crushed material with the deposited carbon at a temperature above about 1700* C. so.

that calcium carbide is formed.

3. The process .of claim 2, wherein the pyrolyzing temperature is between about `950 and about 1050 C.

v4. The process of claim 2, wherein the methane-predominating gas is a natural gas.l

5. The process of manufacturing calcium carbide which comprises pyrolyzing a methane-predominating gas in the ,presence oi crushed calcium oxide at a temperature between about V850 s and about 1150 C. in a pyrolyzing zone while 4excluding appreciable amounts of vextraneous gases from said zone thereby obtaining a mixture of calcium oxide and carbon 'of proper proportions for manufacturing calcium carbide by heat- 10. The process of vmanufacturing calcium oxide-carbon complexes that provide calcium oxide and carbon in efllcient form for uses requiring these materials which comprises pyrolyzing a methane-predominating gas in the presence of crushed calcium oxide at a temperature between about 850? and about l150`C. in a pyrolyzing zone, from which gases other than the hydrocarbon gas and gases produced in situ therefrom and from the calcium oxide are excluded.

11. 'I'he process of claim 10, wherein the crushed particles arebetween about A and about 2 inches" in size. A

12. The processor manufacturing calcium oxide-carbon complexes that provide calcium oxide; .and carbon in etllcient form for uses `requiring these materials which comprises pyrolyzing' a normally gaseous, hydrocarbon in the presence of` crushed calcium oxideat a temperature between about 850 and about 1150D C: in a pyrolyzingzone,

` from which gasesother than the hydrocarbon I whereby non-dusting calcium oxide-carboncomgas and gases produced in situ are excluded plexes are formed which are substantially harder than calcium oxide and which are electrical conductors.

13. A process `which comprises `pyrolyzing a methane-predominating`I gas in the presence of i calcium oxide at a temperature betweenabout 850 C. and about 1400 C. ina pyrolyzing zone while excluding gases other than the methane-predominating gas and gases produced insitu, and correlating the residence time, of the calcium oxide in the pyrolyzing `zone with'the temperature so that the calcium oxide consists essentially of particles impregnated with carbon in a `mol ratio Y of at least 1 to 1.

in g, and then heating said mixture of calcium 1700" C. so that calcium carbide is formed.

6.4 The process ofmanufacturing calcium-carbide whichv comprises passing a moving bed of crushed calcium oxide'through a pyrolyzing zone,

l introducing a methane-predominating gas into said zone while maintaining the zone at a temperature between about 850 and about 1150 C. j by heating same without introducing extraneous gases thereinto, pyrolyzing said methane-predominating gas in said zonewhereby the calcium .oxide is Atransformed into non-dusting calcium i oxide-carbon complexes which lare substantially harderthan calcium oxide, and which are of suitable proportions for manufacturing calcium carl bide by heating. passing said complexes in heated f condition substantially directly into a vcarbide- Ivorming zone, passing said ycomplexes through said carbide-forming zone in the form of a moving bed while heating the complexes to a carbideforming temperature above about 1700" C. but

below lthe melting points o! the complexes and calcium carbide so thatthe calcium oxide-carbon complexes are converted in the solid state to calcium carbide.

7. The process of claim 6 Vwherein a sumcient amount of the calcium oxide-carbon complexes are-recycled to the pyrolyzing zone that the moving bed therein is a conducting charge, and the zone is heated by means of electrical resistance.

`oxide andcarbon at a temperature above about: o

14. A process which comprises pyrolyzing `a norl mally gaseous hydrocarbon in the` presence of calcium oxide at a .temperature between about-.850

C. and about 1400 C. in a pyrolyzing zonewhile excluding gases other than the hydrocarbon gas and gases produced in situ, and correlating the residence time of the calcium oxide in the pyrolyzing zone with the temperature `so that the calcium oxide consists essentially of particles impregnated` withcarbon in a mol ratio of at least 1 to l.

15. A- process which comprises lpyrolyzing a methane-predomina'cing gas in the presence of calcium oxide particles at a tempera ture between` about 850 C. and about 1400 C. in a pyrolyzing zone While excludingfgases other than the methane-predominating 4gasand gases produced in situ, and correlating the residence time of the calcium oxide in the pyrolyzing zone with the temperatur'e so that the major portion of the calcium l oxide particles are impregnated with carbon in a 8. Thel process of claiml 6, wherein the carbideforming zone is heated by means of electrical induction.

9. The process of claim 6, wherein the pyrolyzing zone is maintained at a temperature between about 950 and about 1050 C. i

mol ratio of from 1 to 1 to 4 to 1.

, 16. A continuousV processior the production oi carbon impregnated calcium oxide particles which comprises continuously introducing calcium .oxide particles into a pyrolyzing zone, continuouslypassing upwardly through said calcium oxide particles a normally gaseous hydrocarbon while maintain-I ing a temperature of between about 850 C.`and 

